Method and tool product of differential heat treatment process

ABSTRACT

A tool having a relatively ductile working end for engaging workpieces and a relatively hard non-working portion for driving the tool is disclosed, and a process for making same. The tool is formed with the material in a first state, such as by cold-working, and then only the non-working portion is heat treated to a second state. The working end is thus maintained in the ductile state while the non-working portion is hardened, thus imparting different materials performance characteristics to working end and non-working portion.

FIELD OF THE INVENTION

The invention relates to heat treatment for tools and, in particular, toheat treatment providing the tools with at least two regions ofdifferentially applied heat treatment and corresponding materialsperformance characteristics.

BACKGROUND

Currently, it is well known to provide heat treatment to metalimplements such as handtools, vehicle parts, factory machinery, or anyother metal product for which strength, wear, cyclic life, impact, orother materials characteristics determine the performance of theimplement in its intended or expected usage. Virtually all metalproducts are made from an alloy or mix of elemental materials, the alloytypically having a dominant metal such as iron or aluminum that also isthe dominant factor in the resulting performance characteristics of thealloy and any product made therefrom.

As examples, it is common to fashion a variety of handtools for drivingor removing workpieces such as screws, nuts, bolts, and the like, thesehandtools commonly known as wrenches and socket driver sets, referred toherein collectively simply as drivers. Within the range of both intendedusage and unintended though expected usage for such handtools are a needfor a user to apply high torques through an elongated member includingtorque overloads, a need for a close fit with a workpiece fortransmitting torque thereto, an expectation of high cyclic life beforefailure both in terms of wear and in terms of fracture, and anexpectation of high impact life both in terms of cyclic impact life andsingle-event impacts. To be clearer, a user assumes that a tool willperform as intended with repeated application of torque, that contactsurfaces have a high resistance to wear, and that the user will be ableto mistreat the tool at times, such as by dropping or overtorquing thetool, or even using it as a hammer, as mere examples.

The important factors for providing a driver handtool as described arethe material composition, the steps taken to form the tool, the actualshape of the tool considering stress concentrators, for instance, andthe heat treatment. The most common material for drivers is a steelalloy of iron, carbon, and relatively small amounts of other metals.Formation of the tool in part or in whole may be by any method ormethods, such as forging, casting, stamping, or rolling, etc., andgenerally includes some stage of cold-working in order to shape aworking end for engaging a workpiece. More specifically and as anexample, it is generally practiced to cut a socket recess into a socketdriver for receiving a bolt head or extension socket post.

The overwhelming dominant industry-practice for manufacturing suchdrivers is to provide stock, cold-work the stock to a desired drivershape, and then heat-treat the driver. A first process for heattreatment is hardening including heating the drivers into the austeniticrange and then quenching (either water spray or an oil bath) whichresults in a martensitic structure for the steel. Additional carbon maybe added during this heating step, which is known as case-hardening. Asecond process in the heat treatment is a tempering stage includingagain heating the driver or tool to a temperature below the austenitictransformation temperature, holding the temperature at such level forapproximately 2 hours, and then allowing the tool to cool slowly, suchas with ambient air. Accordingly, the entire tool has a temperedmartensite structure.

Like many metal implements, it is known that there are performancetrade-offs when providing a heat treatment for such drivers. Forinstance, it is known that a high hardness for a steel product impartshigh resistance to wear, yet also results in susceptibility to damagefrom impact or sudden load spikes, as such steel is brittle. In order torelieve or reduce the fragility of the tool, greater ductility may beimparted that results in the tool having a lower yield strength and,thus, being softer, more susceptible to wear, and more susceptible toplastic deformation. The heat treatment and materials performancecharacteristics resulting from the heat treatment for tools such asdrivers are selected to balance these characteristics and tendencies.

Accordingly, there has been a need for an improved heat treatment fortools, particularly drivers and other elongated handtools.

SUMMARY

In accordance with an aspect, a method for heat treating a tool isdisclosed including the steps of forming the tool with a working end forengaging a workpiece and with a non-working portion, directly applying aheat treatment to a first predetermined portion of the tool including atleast a part of the non-working portion to impart a materials state tothe first predetermined portion, and providing no direct heat treatmentto a second predetermined portion of the tool including at least a partof the working end.

In some forms, the method further includes the step of providing aheating device, wherein the step of directly applying a heat treatmentincludes placing the first predetermined portion of the tool within theheating device, and wherein the step of providing no direct heatincludes placing the second predetermined portion of the tool outsidethe heating device. The step of providing a heating device may includeproviding an induction coil.

In some forms, the step of forming the tool includes forming the tool ofa steel alloy, and the step of directly applying a heat treatmentincludes a step of heating to a first temperature permitting transitionto the austenitic materials state, a subsequent step of quenching, afurther subsequent step of heating to a second temperature below thefirst temperature, and a third subsequent step of cooling. The thirdsubsequent step of cooling may include quenching.

In some forms, the step of forming the tool includes the step of formingthe tool from stock material having a predetermined materials state.

In some forms, the method further includes the step of permitting a heattreatment gradient between the at least part of the non-working portionand the at least part of the working end.

In some forms, the heat treatment gradient imparts a transition ofmaterials states between the at least part of the non-working portionand the at least part of the working end.

In some forms, the method of claim 1 wherein the step of forming thetool includes the step of forming a socket driver.

In another aspect, a tool is disclosed including a stem portion directlyheat treated to a hardened materials state, a working end not directlyheat treated, and a transition between the stem portion and the workingend having a heat treatment gradient.

In some forms, tool is formed of steel. The working end may have anannealed state. The working end may be hardened by cold-working.

In some forms, stem portion is generally elongated with a firstdiameter, the working end has a second larger diameter and includes asocket, and the transition varies in diameter between the stem portionand the working end.

In some forms, the stem portion is tempered martensite and at least aterminal portion of the working end is of a state having greaterductility than tempered martensite.

In some forms, the tool may be one of a wrench, a box wrench, a socketdriver, a socket driver extension, a socket, a socket adapter, aratcheting device, a reversible ratchet device, a screwdrivers, orpliers.

In another aspect, a method of forming a tool is disclosed including thesteps of selecting desired materials performance characteristics for aworking end of the tool, selecting a stock material having a statecorresponding to the working end desired materials performancecharacteristics, selecting desired materials performance characteristicsfor a non-working portion of the tool, forming the tool from the stockmaterial, the working end and non-working portion having the stockmaterial state, after forming the tool, altering the state of at least apart of the non-working portion to a state having the selected desiredmaterials performance characteristics therefor.

In some forms, the step of altering includes heat treating the at leastpart of the non-working portion.

In some forms, the step of altering includes directly applying a heattreatment to the non-working end while excepting the working end.

In some forms, the stock has a relatively ductile state, and thenon-working portion state is relatively hard.

BRIEF DESCRIPTION OF THE DRAWINGS

In the Figures, FIG. 1 is side elevational view of a form of a tool ofthe present invention;

FIG. 2 is a front elevational view of the form of FIG. 1 including asocket;

FIG. 3 is an enlarged view of the form of FIG. 1 showing arepresentative heat treatment; and

FIG. 4 is a second enlarged view of the form of FIG. 1 showing a secondrepresentative heat treatment.

DETAILED DESCRIPTION

In forms of the present invention, a tool is provided with adifferential heat treatment so that different portions of the tool areprovided with different materials performance characteristics. In someforms, the tool is an elongated tool and/or a tool used for engagingworkpieces such as a wrench or socket driver component. In a preferredform of the invention, a tool formed in a traditional manner is thensubjected to heat treatment only on a non-working portion thereof. Inother words, as heat treatment is used to select or alter theperformance characteristics of a material, the heat treatment isnon-uniform for the entire tool so that different portions of the toolbenefit from different performance characteristics imparted by thedifferential heat treatment. As will be discussed herein, one form ofsuch tool includes a working end that is in an annealed and thencold-worked state and a non-working portion that is heated and tempered,each followed by a quench, to impart hardness thereto.

Referring initially to FIG. 1, a representative tool 10 is depicted inthe form of a socket extension. As is common for such a tool 10, anelongated handle or stem 12 is provided as a non-working portion andextends to an engaging or working end 14. As will be described ingreater detail, the non-working stem 12 has a first set of materialsperformance characteristics and the working end 14 has a second anddifferent set of materials performance characteristics. The first andsecond sets of materials performance characteristics are imparted bydifferences in manufacturing steps for the stem 12 and working end 14,and principally the differences are imparted by differences in heattreatment.

Generally speaking, the tool 10 may be initially formed to the depictedshape and structure in any manner. Stock is provided in the desiredmaterial, such as a particular grade of steel, and in a particular form,such as rod, bar, etc. The stock is generally provided in an annealedstate so that the steel is relatively soft and ductile. The stock isthen cold-worked to the desired shape. For the representative tool 10,such cold-working includes forming a radiused shoulder 16 at a junctionbetween the working end 14 and the stem 12, and cutting or stamping orotherwise providing a recess in the form of a socket 18 in the workingend 14. The socket 18 as shown is square for receiving a post (notshown) of a socket adapter (either an extension or a socket driver forengaging a workpiece), though the socket 18 itself may be constructed todirectly engage a workpiece, as will be readily understood by oneskilled in the art.

After formation to the desired shape, the tool 10 is heat treated in amanner more controlled than that of the prior art. While the standardpractice is to heat treat the entire device in a uniform manner toprovide uniform materials performance characteristics, the tool 10 ofthe present invention is heat treated to impart different materialsperformance characteristics to at least a part of the working end 14 andto at least a part of the stem 12. In a preferred form, heat treatmentis only applied and directly applied to the stem 12, is not applied tothe working end 14, and a transition region 30 spans over theintersection therebetween. To be clear, the working end 14 is exceptedfrom the heat treatment, and the heat treatment is directly applied tothe stem 12 and not the working end 14, though, as will be discussed, itis recognized that heat bleed is generally unavoidable. Therefore, thetransition region 30 is a result of the unavoidable heat transfer fromthe stem 12, heated to an elevated temperature while the working end 14is not, and the transition region 30 also helps avoid unpredictable andundesirable materials states that may result from an abrupt materialsstate junction between the working end 14 and the stem 12 that may occurfrom attempting to stifle such heat bleed.

In a preferred form, the stem 12 is first hardened and then tempered,the working end 14 generally receiving no heat treatment after formationof the tool 10. For the hardening, the stem 12 is induction heated bybeing positioned within and heated by a heating device such as aninduction coil (not shown), as is known in the art. The stem 12 isheated to a temperature that permits the steel thereof to transitioninto the austenitic range, the temperature being dependent on thecomposition of the steel, as is known in the art. The tool 10 includingthe stem 12 is then quenched in a conventional manner such as with awater or oil bath.

To temper, the stem 12 is again heated to a temperature below that whichpermits transitioning to the austenitic range. This temperature is heldfor approximately two hours, and then the tool 10 including the stem 12are again quenched. In a preferred form of the tool 10, the stem 12 isimparted with a relatively hard tempered martensitic materials state,while the working end 14 is imparted with a relatively ductile annealedstate. More specifically, the stem 12 has a hardness of approximately 50HRc while the working end 14 has a hardness of approximately 20 HRc,while the transition region 30 spanning the junction between the stem 12and working end 14 has some gradient of hardness therebetween.

As a result, the socket 18 of the working end 14 is provided withimproved or optimized performance characteristics, as is the stem 12. Todetail, the socket 18 concentrates stress due to torque or impact atcorners 18 a, shown in FIG. 2. Stress concentrators such as thesecorners 18 a are principal sites of fracture or failure for tools. Byproviding the working end 14 including the socket 18 with a higherductility and lower hardness, the corners 18 a have a greater ability towithstand the stress, thereby resulting in a longer life for the tool10. Additionally, the stem 12 is provided with materials characteristicsthat enable it to better withstand the applied torsional stresses andinadvertent impacts.

Turning now to FIG. 3, a preferred from of the tool 10 is illustrated indetail and in cross-section. The tool 10 is generally cylindrical ofvarying circular dimension in cross-section. The stem 12 itself has agenerally constant cross-section leading to the shoulder 16, and theworking end 14 has a generally constant cross-sectional maximum diameterextending from the shoulder 16. From a junction 15 between the shoulder16 and stem 12 to a distal terminus 17, the illustrated tool 10 has anaxial length L of approximately 1.25 inches, the working end has adiameter of approximately 0.85,″ and the stem 12 has a diameter ofapproximately 0.5 inches.

As stated above, heat treatment is applied to the stem 12 and bleedsinto the shoulder 16 and working end 14. In FIG. 3, the region of fullheat treatment is represented as 100 and bounded by line 100 a. Itshould be noted that the region 100 is a continuous region and portionof the tool 10 and is discussed herein as such, though thecross-sectional nature of FIG. 3 shows such as two regions 100. Thisregion 100 extends towards the central axis X of the tool 10, preferablyso that a central region 102 of the stem 12 that is not fully heattreated is less than 25 percent of the overall diametral size of thestem 12. From the junction 15, the region 100 extends towards the distalterminus 17 and through the shoulder 16 approximately 0.375.″ Thecentral region 102 and the rest of the tool 10 (i.e., the working end 14and shoulder 16) receive only heat bleed or far-field effects due to theheat treatment.

As shown in FIG. 3, the heat bleed and far field effects may extendthough a substantial portion of the working end 14. For the illustratedform, the working end 14 may have a relatively small zero-treatmentregion 110 and bound between the terminus or terminal end 17 and line110 a, such as in the order of 0.2″ and as little as 0.075″ axial lengthfrom the distal terminus 17, that receives no far-field or transitioneffect due to heat bleed. Accordingly, while the heat treated region 100may have a hardness of 50 HRc, as discussed above, and thezero-treatment region. 110 may have a hardness in the range of 20 HRc,the balance of the working end 14 and the shoulder 16 forming thetransition region 30 with a hardness gradient between the regions 100,110. In the illustrated form, the full treatment region 100 extends intothe working end 14 a slight amount, in the order of 0.1″ andapproximately 0.075.″

Within the scope of the present invention is selecting the stock toprovide a portion of the resulting tool 10, such as the working end 14,with desired performance characteristics. As stated above, in forms ofthe tool 10, the working end 14 receives no heat treatment. Accordingly,the materials performance characteristics are imparted by the materialsstate of the stock material and the formation steps such as cold-workingapplied to the stock material that serve to reduce the ductility.Therefore, the desired resulting materials state for the working end 14can be accommodated by an appropriate selection of stock. For instance,stock material may be cold rolled, or hot rolled, etc., or the stock mayotherwise be prepared prior to formation of a plurality of tools 10therefrom.

As an additional example of heat treatment, FIG. 4 is provided. As canbe seen, a working end 14 is depicted for the tool 10 with azero-treatment region 120 that does not receive heat treatment. A numberof the benefits of the heat-treatment, as described herein, is theretained ductility or softness for the portion of the working end 14 indirect cooperation with another component such as a post of a driver ora workpiece, as examples. Accordingly, the zero-treatment region 120illustrated is representative of a minimal (though not necessarily thelowest minimum) amount of zero-treatment region 120.

In like manner, FIG. 4 also shows a full-treatment region 130 that isreduced in comparison to full-treatment region 100 of FIG. 3. Theelongated stem 12 of the tool 10 preferably receives at least some heattreatment so that there is the depicted minimal (though, again, notnecessarily lowest minimum) amount of full-treatment region 130. In amore preferred form, the full-treatment region 130 extends through theshoulder 16.

The tool 10, as described, may be a variety of known tools includingwrenches including box wrenches, socket drivers, socket driverextensions, sockets or socket adapters, may be ratcheting devicesincluding reversible ratchet devices, and may be screwdrivers or pliers,as should be clear. It should also be clear that the principalsdescribed herein may be applied to non-steel tools so that a working endis allowed to maintain a more ductile state while a materials state fora non-working portion is hardened by a differential heat treatmentprocess to provide different materials characteristics. It should alsobe noted that the entire tool may be quenched after the tempering stage,thus accelerating the production time in comparison to the typicalair-cool step.

While the invention has been described with respect to specific examplesincluding presently preferred modes of carrying out the invention, thoseskilled in the art will appreciate that there are numerous variationsand permutations of the above described systems and techniques that fallwithin the spirit and scope of the invention as set forth in theappended claims.

1.-20. (canceled)
 21. A method for heat treating a tool, the methodcomprising the steps of: forming the tool with a stem portion having afirst end adapted to couple to a driver and receive an amount of torquefrom the driver, a shoulder portion extending from the stem portionopposite the first end, a working portion extending from the shoulderportion opposite the stem portion and including a recess adapted toreceive a device adapted to engage a work piece, and a zero-treatmentregion extending from the working portion to an end of the tool andforms only an opening of the recess; heat treating the stem portion to afirst depth to form substantially tempered martensite steel to the firstdepth, wherein the first depth is measured in a radial direction from anexternal surface of the stem portion towards a center of the stemportion; and providing no direct heat treatment to the shoulder andworking portions and the zero-treatment region, wherein the shoulder andworking portions are at least partially comprised of a materialincluding tempered steel created by residual heat from the heattreating, and are substantially free of tempered martensite steel afterthe heat treating, and wherein the zero-treatment region is comprised ofa material free of tempered martensite steel and tempered steel.
 22. Themethod of claim 21, wherein the step of heat treating includes placingthe stem portion in a heating device.
 23. The method of claim 21,wherein the step of heat treating includes placing the stem portion inan induction coil.
 24. The method of claim 21, wherein the step offorming the tool includes forming the tool of a steel alloy, and whereinthe step of heat treating includes: heating the stem portion to a firsttemperature; quenching the stem portion; heating the stem portion to asecond temperature below the first temperature; and cooling the stemportion.
 25. The method of claim 24, wherein the step of coolingincludes quenching.
 26. The method of claim 21, wherein the step offorming the tool includes forming the tool from stock material having apredetermined materials state.
 27. The method of claim 21, wherein thestep of forming the tool includes forming the zero-treatment region witha hardness of about 20 HRc.
 28. The method of claim 21, wherein the stepof heat treating includes heat treating the stem portion to the firstdepth and the first depth forms at least 75% of an overall diametricsize of the stem portion.
 29. The method of claim 21, wherein the stepof forming the tool includes the step of forming a socket driverextension.
 30. A method of forming a tool, comprising: forming the toolfrom a base material, the tool having a working portion adapted toengage a work piece and a non-working portion; heat treating at least apart of the non-working portion; providing no direct heat treatment toan end of the working portion, wherein a portion of the tool between theworking and non-working portions is subject to residual heat from theheat treating.
 31. The method of claim 30, wherein the step of heattreating includes heat treating at least the part of the non-workingportion to a first depth to form substantially tempered martensite steelto the first depth, wherein the first depth is measured in a radialdirection from an external surface towards a center of the non-workingportion.
 32. The method of claim 30, wherein the step of providing nodirect heat treatment includes subjecting the portion of the toolbetween the working and non-working portions to residual heat from theheat treating, wherein the portion of the tool between the working andnon-working portions is at least partially comprised of a materialincluding tempered steel and substantially free of tempered martensitesteel after the heat treating, and wherein the end of the workingportion is comprised of a material free of tempered martensite steel andtempered steel.
 33. The method of claim 30, wherein the step of formingthe tool includes forming the tool of a steel alloy, and wherein thestep of heat treating includes: heating the non-working portion to afirst temperature; quenching the non-working portion; heating thenon-working portion to a second temperature below the first temperature;and cooling the non-working portion.
 34. The method of claim 33, whereinthe step of cooling includes quenching.
 35. The method of claim 30,wherein the step of forming the tool includes forming the tool fromstock material having a predetermined materials state.